Two-piece safety mechanism for ceiling fans

ABSTRACT

A two-piece safety mechanism for ceiling-mounted fans comprises a first and second cable. The first cable has a first fastener extending from a first end and a first connector extending from a second end. The first fastener is for operable association with a first fastening mechanism for securing the first cable to a fan. The second cable has a second fastener extending from a first end. The second fastener is for operable association with a second fastening mechanism for securing the second cable to a ceiling support. The second cable also has a second connector extending from a second end, which is releaseably attachable to the first connector to form a continuous cable. The claimed invention also provides for a ceiling fan having the two-piece safety mechanism for retaining the fan in close proximity to the ceiling support if its normal mounting apparatus should fail.

CROSS REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY

This application is a continuation-in-part of application Ser. No.10/187,832, filed Jul. 3, 2002, for John C. Marshall, titled “Two-PieceSafety Mechanism for Ceiling Fans,” the disclosure of which isincorporated herein by reference and to which priority is claimedpursuant to 35 U.S.C. § 120.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a two-piece safety mechanism for usewith ceiling fans. A first cable attaches to a ceiling fan, and a secondcable attaches to a ceiling support. The first and second cables havefirst and second connectors, respectively, which releaseably attach toform a continuous cable that retains the ceiling fan in close proximityto a ceiling support if the fan's normal mounting apparatus should fail.

2. Description of the Prior Art

A conventional ceiling fan consists of a motor suspended from a ceilingwith radially extending fan blades operably associated with the motor. Acylindrical body, or downrod, is secured to the motor on one end. On theopposing end, the downrod includes a hanger ball. The hanger ball isgenerally secured to a mounting bracket, and the mounting bracket issecured to a support from a ceiling support. Therefore, the downrod,hanger ball, and mounting bracket work in conjunction to hang the fanfrom the ceiling support. Electrical wiring from the fan is generallyattached to an electrical box in the ceiling. It is known in the artthat such ceiling mounted fans may be subject to falling for variousreasons.

A ceiling fan may fall if it is installed improperly. The mountingbracket must be properly secured to the ceiling support. Furthermore,the support must be capable of holding the fan. If not, the fan mayfall, damaging the fan or other property, or even causing personalinjury. Even if the ceiling support can hold the weight of the fan, themounting bracket may fail.

In addition, many fans are manufactured with metric bolts, screws orcorresponding threads. However, some electrical boxes, especially thosemanufactured in the United States, have standard threads. When a metriccomponent is fastened to a standard component, a proper fit is notachieved and the attachment may pull free.

Ceiling fans may also fall if faulty or defective materials are used inthe fan components. Many mounting brackets manufactured today arelargely composed of zinc. When casting zinc brackets, the zinc must notcontain impurities. Impurities in a cast zinc mounting bracket may causebrittleness over time and break. Although zinc brackets today may becast properly, faulty mounting brackets are always a possibility so longas zinc is used in their manufacture.

In addition, ceiling fans are sometimes unbalanced. An unbalanced fancontinuously rocks back and forth. The constant, repetitive rockingmotion can loosen electrical or mounting connections, cause metalfatigue, and ultimately cause the fan to fall.

To curb the installation of faulty ceiling fans that are prone tofalling, and the installation of poorly secured electrical boxes, theNational Electrical Code (NEC) Organization has approved only certainfan and electrical box designs, and mandated that only the approveddesigns be used on new fan installations. Although this mandate ishelpful, it does not entirely prevent the above noted problems.Therefore, there is a need for safety mechanisms that will prevent thefan from falling, and potentially causing personal or property damage.

Various designs in the prior art attempt to solve the above notedproblems with ceiling fans, and thereby reduce the possibility that thefan will fall. Some designs require that the mounting bracket beattached to the ceiling support using additional bolts or screws.However, such designs do not allow for easy installation or removal,given additional fasteners must be secured to the ceiling support.Likewise, removal of the fan after it is initially secured is difficult,requiring the removal of the additional fasteners.

Other designs include a single safety cable, which is connected to thefan by one end and to the ceiling support by the opposing end. Thisdesign may prevent the fan from falling if the fan mounting should fail,but complicates installation. In order to properly secure a singlesafety cable to the ceiling support, the fan and mounting bracket mustbe out of the way. The single cable must first be attached to the fan,and then attached to the ceiling support before the mounting bracket hasbeen secured to the ceiling support (if the mounting bracket is attachedbeforehand, the single cable may not be properly secured). In thealternative, the single cable could first be attached to the ceilingsupport. However, the same problems arise. Specifically, the fan wouldfirst need to be attached to the mounting bracket, and then the singlecable attached to the fan. Thereafter, the fan and mounting bracketwould be secured to the ceiling support. Installation of the singlesafety cable mechanism is therefore inconvenient and difficult.

In addition, many conventional fan designs require partial un-assemblywhen attaching such a single safety cable mechanism. Thus, installationis further complicated given such un-assembly and subsequent re-assemblywould be required when hanging the fan, instead of when the fan is onthe floor. Therefore, the single safety cable is not a practicalsolution. Subsequent removal of the fan, for cleaning, maintenance,replacement, etc., is also complicated when using a single safety cablefor similar reasons.

As such, a safety cable mechanism is needed which prevents a ceiling fanfrom falling, while maintaining simple and efficient installation andsubsequent removal procedures. The present invention provides for atwo-piece safety mechanism for ceiling mounted fans, which is easy toinstall and prevents the fan from falling more than a few inches shouldits normal mounting apparatus fail.

SUMMARY OF THE INVENTION

A two-piece safety mechanism for ceiling-mounted fans comprises firstand second cables. The first cable has a first fastener extending from afirst end and a first connector extending from a second end. The firstfastener is for operable association with a first fastening mechanismfor securing the first cable to a fan. The second cable has a secondfastener extending from a first end. The second fastener is for operableassociation with a second fastening mechanism for securing the secondcable to a ceiling support. The second cable also has a second connectorextending from a second end. The second connector is releaseablyattachable to the first connector, so that the first and second cablesmay form a continuous cable.

The present invention also relates to a ceiling fan including atwo-piece safety mechanism. The ceiling fan with a two-piece safetymechanism comprises a mounting bracket for securing to a ceilingsupport, a ceiling fan for securing to the mounting bracket, and thetwo-piece safety mechanism described above. The ceiling fan comprises amotor, a motor housing having a plurality of radially extending fanblades operably associated with the motor, a downrod having a hangerball for hanging the ceiling fan from the mounting bracket, andelectrical wires associated with the motor. The first fastener of thefirst cable is secured to the fan, and the second fastener from thesecond cable is secured to the ceiling support. The first and secondconnectors from the first and second cables may be releaseably attachedto form a continuous cable. The continuous cable retains the fan inclose proximity to the ceiling support if the mounting bracket fails.

A method of securing a ceiling fan to a ceiling support comprises thefollowing steps: securing a first end of a first cable to a ceiling fan;securing a first end of a second cable to a ceiling support; securing amounting bracket to the ceiling support; hanging the ceiling fan fromthe mounting bracket; and connecting a second end of the first cable toa second end of the second cable so that the first and second cablesattach to form a continuous cable.

The claimed invention also provides for a mounted ceiling fan comprisinga mounting bracket secured to a ceiling support, a downrod having ahanger ball secured to the mounting bracket, a fan secured to thedownrod, a first cable secured to the downrod, and a second cablesecured to the ceiling support. The first and second cables furtherinclude first and second connectors, respectively, which are releaseablyattached forming a continuous cable for retaining the fan in closeproximity to the ceiling support should the mounting bracket fail.

In a second embodiment of the present invention, a safety mechanism forceiling-mounted fans is provided, comprising a cable having a fastenerextending from a first end and a connector extending from a second end.The fastener is for operable association with a first fasteningmechanism for securing the cable to a fan. A shaped body, preferablyL-shaped, is also provided, having a first end and a second end. Thefirst end has a first opening for operable association with a secondfastening mechanism for securing the shaped body to a ceiling support.The second end of the shaped body has a second opening configured forreceiving the connector for releasably securing the connector therein.

A hanger ball for hanging a ceiling fan from a support comprises a majorportion for operable association with a mounting bracket of a ceilingfan. A first cable extends from the major portion. The first cable has aconnector extending from a first end, and a second end integrally moldedwith the major portion. The connector is operably associated with asecond cable having a fastener. The connector and fastener arereleaseably attachable to form a continuous cable. Alternatively, thesecond end may include a fastener that is secured to the hanger ballusing a fastening mechanism.

An electrical box for securing to a support comprises a wall defining aninner chamber for connecting electrical wires therein. A first cableextends from the wall. The first cable has a fastener extending from afirst end, and a second end integrally molded with the wall. Thefastener is operably associatable with a second cable having aconnector. The fastener and connector are releaseably attachable to forma continuous cable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a two-piece safety mechanism accordingto the present invention;

FIG. 2 is an elevational view of a continuous cable according to thepresent invention;

FIG. 3 is a fragmentary exploded assembly view of a second connectoraccording to the present invention;

FIG. 4 is a fragmentary exploded prospective view of a first connectoraccording to the present invention;

FIG. 5 is an assembly view of a ceiling fan with the two-piece safetymechanism and a second installation method for the present invention;

FIG. 6 is an exploded assembly view of a ceiling fan with the two-piecesafety mechanism and a third installation method for the presentinvention;

FIG. 7 is an exploded view of an L-shaped body according to a secondembodiment of the present invention;

FIG. 8 is a perspective view of a hanger ball according to a thirdembodiment of the present invention, with portions molded within thehanger ball shown in phantom;

FIG. 9 is a perspective view of an electrical box according to a fourthembodiment of the present invention, with portions molded within theelectrical box shown in phantom; and

FIG. 10 is a perspective view of a hanger ball according to a fifthembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As best shown in FIG. 1, a two-piece safety mechanism 2 for a ceilingmounted fan comprises a first cable C1 and a second cable C2. Firstcable C1 has a first fastener 4 extending from a first end 6, and afirst connector 8 extending from a second end 10. Second cable C2 has asecond fastener 12 extending from a first end 14, and a second connector16 extending from a second end 18. Second connector 16 is operablyassociated with first connector 8 for releaseably attaching first cableC1 and second cable C2 to form a continuous cable, as best shown in FIG.2. The continuous cable may be easily detached, reforming first cable C1and second cable C2 by simply disconnecting first connector 8 fromsecond connector 16.

As best shown in FIG. 3, second connector 16 is an elongate body havingan opening 20, which is configured to receive first connector 8. Secondconnector 16 has opposed first and second major surfaces 22 and 24,respectively. Opening 20 extends through major surfaces 22 and 24. Aside 26 extends between major surface 22 and major surface 24. First andsecond slots 28 and 30, respectively, extend through side 26 and intoopening 20, and cooperate with cylindrical opening 20 for receivingfirst connector 8 and second end 10 of first cable C 1.

Side 26 of second connector 16 has a first end 32 and a second end 34,as best shown in FIG. 3. Second cable C2 extends from second connector16 proximate first end 32. Opening 20 is proximate opposing second end34. First slot 28 extends from first major surface 22 through side 26 toa point intermediate to second major surface 24. This intermediate pointpreferably is equidistant from major surfaces 22 and 24. Second slot 30extends through side 26 to opening 20 intermediate major surfaces 22 and24, extending from the intermediate point of first slot 28 to second end34 of side 26. Second slot 30 preferably is perpendicular to first slot28. Second slot 30 preferably is parallel to major surfaces 22 and 24.In addition, second slot 30 may have ridges 36 for securing first cableCl and first connector 8.

As best shown in FIG. 4, first connector 8 preferably is cylindrical,with flat surfaces 38 and 40. First connector 8 is sized to be receivedin opening 20 of second connector 16. First connector 8 is received inopening 20 so that second end 10 of first cable Cl may be aligned withfirst slot 28, as best shown in FIG. 3. First connector 8 is insertedinto opening 20. Second end 10 of first cable Cl is aligned with, andinserted into, slot 28. Flat surfaces 38 and 40 may be flush with majorsurfaces 22 and 24 after insertion of first connector 8 into opening 20.First connector 8, along with second end 10 of first cable C1, is movedinto second slot 30 by swiveling first connector 8 within opening 20.Second end 10 of first cable C1 thereafter moves into second slot 30 andpast ridges 36, so that first cable C1 extends from slot 30 proximatesecond end 34 of second connector 16. First and second slots 28 and 30,along with ridges 36 cooperate to releaseably attach first and secondcables C1 and C2, thereby forming a continuous cable. The first andsecond connectors may be made of zinc, or other suitable materials.

In a preferred embodiment of the present invention, two-piece safetymechanism 2 is operably associated with a ceiling fan. Mountingcomponents for a ceiling fan with safety mechanism 2 are best shown inFIG. 5. Generally, a ceiling fan includes a fan motor 50, which isattached to a downrod 52. Downrod 52 includes a hanger ball 54, which isoperably associated with a mounting bracket 56 for hanging the ceilingfan from ceiling support S. Hanger ball 54 fits into a correspondingportion B of mounting bracket 56. Mounting bracket 56 is secured toceiling support S with a plurality of mounting screws 58. A canopy 60may cover hanger ball 54 and mounting bracket 56 for aesthetic purposes,and is secured to mounting bracket 56 using canopy screws 62. Thesecomponents of the ceiling fan are well known in the art.

First cable C1 may be secured to downrod 52 above hanger ball 54, asshown in FIG. 5. Downrod 52 includes a corresponding opening O in whichfirst fastener 4 may be secured using first fastening mechanism 64.First fastener 4 includes an opening 66 through which first fasteningmechanism 64 passes, as best shown in FIG. 2. First fastening mechanism64 may then be secured in corresponding opening O of downrod 52, therebysecuring first cable C1, as shown in FIG. 5. In the preferredembodiment, first fastening mechanism 64 is a pin. However, any knownfastening mechanism may be used, such as a bolt or a screw. First cableC1 is preferably secured to the ceiling fan before the fan is beingsecured to mounting bracket 56.

As best shown in FIG. 2, second cable C2 may be secured to the ceilingsupport S, before mounting bracket 56 is secured to the ceiling supportS. Second fastener 12 is secured to ceiling support S using a secondfastening mechanism 68. Second fastening mechanism 68 may also includeany known fastening mechanism, but is preferably a screw or bolt. Secondfastener 12 also includes an opening 70, operably associated with secondfastening mechanism 68.

It should be understood, however, that first cable C1 may be also besecured to the ceiling support S. First fastener 4 may be secured toceiling support S using second fastening mechanism 68. Likewise, secondfastener 12 of second cable C2 may be secured in opening O of downrod 52using first fastening mechanism 64. In this way, first cable C1 andsecond cable C2 are interchangeable.

In a preferred installation of a ceiling fan having two-piece safetymechanism 2, second fastener 12 is secured directly to ceiling support Susing second fastening mechanism 68, as best shown in FIG. 2. Then,mounting bracket 56 may be secured to ceiling support S proximatesecured second fastener 12 using mounting screws 58. Having alreadysecured first fastener 4 to the ceiling fan as explained above, theceiling fan may then be secured to mounting bracket 56 withcorresponding hanger ball 54 on downrod 52. First connector 8 may thenbe releaseably secured to second connector 16, as explained above, alongwith the associated electrical wiring for the ceiling fan.

First connector 8 and second connector 16 may be easily joined togetherto form a continuous cable. The continuous cable retains the fan inclose proximity to ceiling support S if mounting bracket 56 should fail.First connector 8 and second connector 16 fit securely together, withridges 36 securing first end 6 of first cable C1 within second slot 30,so that vibrations from operation of a fixture do not cause first andsecond connectors 8 and 16 to detach.

A second installation for the claimed invention is best shown in FIG. 5,which depicts various mounting components for a ceiling fan, describedabove. Hanger ball 54 is operably associated with mounting bracket 56,so that hanger ball 54 fits in corresponding portion B of mountingbracket 56. Mounting bracket 56 is first secured to ceiling support Susing mounting screws 58. One of the plurality of mounting screws 58 isused to secure second fastener 12. As best shown in FIG. 5, one of themounting screws 58 is passed through opening 70 of second fastener 12,through the respective area in mounting bracket 56, and into ceilingsupport S. Thus, one of the mounting screws 58 functions as secondfastening mechanism 68; First fastener 4 of cable C1 is secured to theceiling fan as explained above.

A third method of installation of the claimed invention is best shown inFIG. 6. Again, first fastener 4 of cable C1 is secured to the ceilingfan as explained above. However, second cable C2 is secured to anelectrical box E prior to securing mounting bracket 56 to ceilingsupport S, as shown in FIG. 6. Generally, electrical box E is secured toceiling support S by a plurality of electrical box fasteners 72, such asscrews or bolts. One of the electrical box fasteners 72 may be used assecond fastening mechanism 68, as shown in FIG. 6, wherein secondfastener 12 is secured to electrical box E using one of electrical boxfasteners 72, which in turn is fastened into ceiling support S. Thismethod of installation may be desirable when an NEC approved electricalbox is mounted in ceiling support S.

The two-piece safety mechanism of the present invention makesinstallation on ceiling fans very simple. First cable C1 is attached tothe ceiling fan when it is being assembled on the floor. Second cable C2is attached to the ceiling support (or electrical box) before the fan ishung from mounting bracket 56. After installing the fan, cables C1 andC2 may be easily joined together using the specially designed first andsecond connectors, 8 and 16. In addition, if the fan ever requiresservicing, cleaning, replacing fan parts, etc., cables C1 and C2 may beeasily detached. The two cables are simply disconnected after otherdisconnections have been made.

A second embodiment of the invention is best shown in FIG. 7, whereinsecond cable C2 has been modified, and the intermediate cable betweensecond fastener 12 and second connector 16 has been eliminated. As shownin FIG. 7, second fastener 12 a and second connector 16 a are molded asa single shaped body C3, preferably L-shaped, though shaped body C3 neednot be at a right angle. Shaped body C3 includes elements correspondingto second fastener 12 and second connector 16, which have been explainedabove, and correspondingly numbered. Second fastener 12 a includes anopening 70, which is operably associated with second fastening mechanism68. Shaped body C3 is secured to ceiling support S using secondfastening mechanism 68, as explained above. Second connector 16 a isoperably associated with first connector 8 as explained above, andincludes all corresponding elements, as shown in FIG. 7. Shaped body C3therefore has corresponding openings 70 and 20, which are preferablyperpendicular to each other. Slots 28 and 30 are operably associatedwith opening 20, and slot 30 is preferably parallel with opening 20, andcontains ridges 36 as described above. However, it should be understoodthat shaped body C3 may also be secured in opening O of downrod 52 usingfirst fastening mechanism 64.

In a third embodiment, the first cable and hanger ball have beenintegrated into a single unit. As best shown in FIG. 8, hanger ball 80includes a first cable C1′ extending from an upper surface 82. Firstcable C1′ is preferably molded into hanger ball 80 at the time ofmanufacture. Aside from the integration of first cable C1′ into hangerball 80, hanger ball 80 has a configuration similar to hanger ball 54.Therefore, hanger ball 80 is operably associated with mounting bracket56, so that hanger ball 80 fits in corresponding portion B of mountingbracket 56, as best shown in FIG. 6. In addition, hanger ball 80 isoperably associated with downrod 52. Hanger ball 80 may have a smoothchannel for receiving downrod 52, which may be secured therein withscrews, pins, or the like as known in the art. Alternatively, hangerball 80 may have a threaded channel 84, as best shown in FIG. 8, forthreadably receiving a downrod.

First cable C1′ is not separately secured to downrod 52, because firstend 6′ is secured directly to upper surface 82 of hanger ball 80.Preferably, first cable C1′ includes a portion 84 extending from firstend 6′ that is molded within hanger ball 80. First cable C1′ alsoincludes a first connector 8 extending from second end 10. As such,first connector 8 is operably associated with second connector 16 ofsecond cable C2 for releaseably attaching first cable C1′ and secondcable C2 to form a continuous cable, as described above.

Installation of the third embodiment of the present invention on ceilingfans is simplified given first cable C1′ need not be separately securedto downrod 52. Second cable C2 is attached to the ceiling support (orelectrical box) before the fan is hung from mounting bracket 56. Afterinstalling the fan and securing hanger ball 80 to mounting bracket 56,cables C1′ and C2 are easily joined together as described above.

Alternatively, second cable C2 and electrical box E may be integratedinto a single unit. As best shown in FIG. 9, a fourth embodiment of thepresent invention provides an electrical box 90 having a second cableC2′ extending from side surface 92. Second cable C2′ is preferablymolded into electrical box 90 at the time of manufacture. Alternatively,second cable C2′ may be secured to side surface 92 using screws, bolts,pins or the like prior to installation of electrical box 90. Thus,electrical box 90 may be provided to a user having second cable C2′already secured thereto. Electrical box 90 may be manufactured fromsheet metal, plastic or any other approved material.

Installation of the safety mechanism according to the fourth embodimentis streamlined because the user is not required to secure second cableC2′ to an electrical box, given it is already incorporated intoelectrical box 90. Second cable C2′ preferably includes a portion 94extending from first end 14′ that is molded within electrical box 90.Second cable C2′ includes a second connector 16 extending from a secondend 18. As such, second connector 16 is operably associated with firstconnector 8 of first cable C1 for releaseably attaching second cable C2′and first cable C1 to form a continuous cable, as described above.

Preferably, electrical box 90 is provided with first cable C1, so thatthe installer has all of the necessary components for installation ofthe safety mechanism of the present invention when electrical box 90 isinitially installed. Electrical box 90 may be secured to ceiling supportS using a plurality of electrical box fasteners 72, as best shown inFIG. 6.

In a fifth embodiment, cable C1 may be secured directly to a hanger ball100 with a fastening mechanism 102, as best shown in FIG. 10. Hangerball 100 includes a corresponding opening O′ in which fastener 4 ofcable C1 may be secured using fastening mechanism 102. Fasteningmechanism 102 is passed into opening O′, through fastener 4, and into areceiving portion 104, thereby securing first cable C1 to hanger ball100. Fastening mechanism 102 is preferably a screw, but may be a bolt, apin, or the like. Opening O′ is preferably a recessed opening, whichallows fastening mechanism 102 to be recessed from an outer surface 106of hanger ball 100. Preferably, fastening mechanism is a stainless steelscrew, which is screwed into opening O′ so that the head of the screwdoes not extend outwardly from outer surface 106. Hanger ball 100 mayinclude supports 108, 109, such as metal plates, which include openingscorresponding to and aligned with opening O′ and receiving portion 104.Adequate space is provided between supports 108, 109 to allow fastener 4of cable C1 to be secured therebetween. Thus, fastening mechanism 102may be screwed into opening O′, through support 108, through the openingof fastener 4 (as best shown in FIG. 2), and into receiving portion 104of support 109.

Second cable C2 may be secured to support S or electrical box E, asdescribed above. Cables C1 and C2 are then releasably attached.Alternatively, cable C1 may be secured to second cable C2′ of electricalbox 90.

It will be apparent to one of ordinary skill in the art that variousmodifications and variations can be made in construction orconfiguration of the present invention without departing from the scopeor spirit of the invention. Thus, it is intended that the presentinvention cover the modifications and variations of the invention,provided they come within the scope of the following claims and theirequivalents.

1. A two-piece safety mechanism for ceiling-mounted fans, comprising: a first cable having a first fastener extending from a first end and a first connector extending from a second end, said first fastener for operable association with a first fastening mechanism for securing said first cable to a fan; and a second cable having a second fastener extending from a first end, said second fastener for operable association with a second fastening mechanism for securing said second cable to a ceiling support, and said second cable having a second connector extending from a second end, said second connector releaseably attachable to said first connector to form a continuous cable. 2-57. (canceled) 